Metal Mesh Welding Layout for Fast Format Changes
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Solution Overview
Problem
Existing apparatuses for producing metal meshes are inefficient in creating close meshes with varying rod diameters, require complex and costly repositioning of feed units, and result in significant downtime and waste during format changes, limiting flexibility and increasing maintenance needs.
Innovation Solution
An apparatus comprising two coordinated operating groups to feed and weld longitudinal and transverse rods with adjustable pitches and diameters, allowing for the production of metal meshes with desired sizes and configurations, featuring a control unit for programmable operation and reduced component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If individual feed units are repositioned to produce close meshes or meshes with different rod diameters, then manufacturing flexibility is improved, but equipment downtime and operational complexity increase significantly
Solution Approach 1:
The patent implements a dynamic positioning system where the feed unit can be moved along the longitudinal axis of the machine frame. This allows the feed unit to be repositioned to different locations corresponding to different longitudinal rod positions, enabling production of meshes with varying rod diameters and pitches without requiring complete disassembly or complex reconfiguration of the entire system
Solution Approach 2:
The feed unit is designed as a universal, multi-functional component that can handle different rod diameters and positions. By making the feed unit itself adaptable rather than having dedicated feed units for each rod position, the system achieves versatility while minimizing downtime through standardized replacement and positioning procedures
2Manufacturing precision
If multiple individual feed units are used to supply longitudinal rods, then rod positioning precision is improved, but device complexity and maintenance requirements increase
Solution Approach 1:
The system segments the feeding function into two distinct phases: first, the feed unit supplies individual longitudinal rods one at a time to the welding unit; second, these rods are positioned and welded in sequence. This segmentation allows precise control of each rod independently while simplifying the overall system architecture compared to having all feed units operating simultaneously
Solution Approach 2:
Instead of having multiple feed units supply all longitudinal rods simultaneously (the conventional approach), the patent inverts the process by supplying longitudinal rods sequentially one at a time. This inversion simplifies the feed unit design and reduces complexity while maintaining positioning precision through controlled, sequential delivery to the welding position
3Adaptability or versatility
If feed units are repositioned for format changes, then adaptability to different mesh specifications is improved, but productivity during repositioning operations deteriorates
Solution Approach 1:
The feed unit is designed with preliminary positioning capabilities, allowing it to be pre-positioned at different locations along the machine frame corresponding to different mesh formats. This preliminary preparation enables quick format changes without requiring complex real-time adjustments during production, thereby minimizing interruption to the production flow
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient production of metal meshes with flexible rod configurations and reduced setup and downtime, improving adaptability and reducing maintenance requirements.
Implementation Method 1
a first welding unit to weld on each occasion to said first longitudinal rods the transverse rod fed by the second feed group
Data Source
Figure 1
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Figure 3~5
AI summary
Apparatxis (10) to make a metal mesh (11) having longitudinal rods (13, 15) and transverse rods (14) which have a diameter and reciprocal pitch defined on each occasion according to requirements, comprising a first operating group (16) and a second operating group (34) disposed in sequence and functionally coordinated, to obtain a reticular semi-worked product (12) that is completed to make the desired metal mesh (11).